Basic Mechatronics system

Unit I
Basic Mechatronics System
 Introduction and definition of Mechatronics :
Definition of mechatronics –
Mechatronics, also called mechatronics engineering, is an interdisciplinary branch of
engineering that focuses on the integration of mechanical, electronic and electrical engineering
systems, and also includes a combination of robotics, electronics, computer science,
telecommunications, systems, control, and product engineering.

It is the extension and the completion of mechanical systems with sensors and micro computers
which is the most important aspect.
Advantages & disadvantages of Mechatronics -
Advantages of Mechatronics
1) High level of integration
2) Increased functionality and better design.
3) More use of electronics and software instead of mechanical function.
4) Assumes responsibility for process and operation with little interference of operators.
5) Uses artificial intelligence and intelligent process control.
6) High reliability and safety.
7) Improved and less expensive controls.

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Disadvantages of Mechatronics
1) The initial cost is very high.
2) The complicated design and system.
3) The repair and maintenance is complex.
4) Its replacement is so difficult, that it is difficult to change the old system to the new system.
 Application of Mechatronics :

1) Electronic home appliances

2) Electronic entertainment products
3) Engine systems (cars)
4) Large scale application
5) Automotive mechanics.
6) VCRs and CD players.
7) Document scanner.

 Scope of Mechatronics in Industrial Sector :

 Better design of products.
 Better process planning.
 Reliable and quality oriented manufacturing.
 Intelligent process control.

 Block diagram of Mechatronics with various components with example :

Generally a measurement system consists of 3 basic elements.
1. Sensor/transducer.
2. Signal conditioner.
3. Display/read out devices.
In addition to the above, electrical power is also required.

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Functions of each elements of measurement system:

1) Sensor/transducer unit: -
The heart of any measurement or control system is sensor/transducer. Sensor/transducer is
a device it converts the one form of energy to another form. Sensor/transducer it senses the physical
phenomenon to be measure and transform it from one form to another form (generally electrical
form). The output of this unit is input to the signal conditioner which is next element.

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2) Signal conditioner unit:

This unit senses the output signals of sensor and converts it into suitable, measurable level
of signals. An amplifier is acts as a signal conditioner in the figure.
The following functions of signal conditioners are:
a. Amplification of signals: The level of signals from the transducer may be of low level for the
next use and hence need to be amplified (increased).
b. Attenuation: Similarly the level of signals from the transducer may be of higher level for the
next use and hence need be attenuated (decreased).
c. Filtering: signals from the transducer may contain some other undesirable signals which need
to be filtered or eliminated before it is used. Otherwise a corrupt output will be generated.
d. Analog to digital conversion (ADC): The signals from the transducer may be analog in nature
and if these signals were to be used as input to electronic system/computer system, they need to be
converting to digital form. Similarly sometimes we use DAC.
3) Display/read out unit: It displays the output of signal conditioner unit and this display will be the
quantitative form of measured. Display unit may be either of analog (dial gauge) and digital (LED)
type.
Example of Measurement system: Digital thermometer principle

 Control system:
The word control means „to regulate‟, „manipulate‟, and „command‟.
Examples:
1. A container is to be filled with water from a tap. Once the water fills the container, the valve is
closed (that is spilling of water is avoided) by observation from a human being who senses the
filling and based on the observation closes the valve.
2. The driver applies the brake of the vehicle, when he/she observes red traffic light.
Definition of Control system:
A group of devices/elements which maintains the required output based on the predefined
value by controlling the parameter responsible for output.
Classification of control system:
1. Open loop control system (NO FEEDBACK control system).
2. Closed loop control system (WITH FEEDBACK control system).

1. Open loop control system (NO FEEDBACK control system):

In which the output is dependent on the input, but input is independent of output is called open
loop control system.

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Elements of closed loop control system:

The basic elements of a closed loop control system are:
1. Comparison element.
2. Control unit.
3. Correction unit.
4. Process unit.
5. Feedback unit.
Functions of each elements of a closed loop system:
Comparison element: this unit compares the reference value with feedback value
and produces an error signal.
Error = reference value – feedback value
Control unit: Control unit analyses the error signal and decides what action is to be taken.
Correction unit: the modified signal from the control unit will be received by the
correction unit which produces a change in the process to correct or change the controlled
condition.
Process unit: process unit is the unit which is being controlled.
Examples:
1. Hand reaching an object.

This is an example of closed loop control system.

 A person wants to reach for an object.
 Position of the object is given as reference, feedback signals and the eyes compares
the actual position of the hands with reference to the position of the object.

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 Error signal is given to the brain.

 Brain manipulates this error and gives signals to the hands.
 This process continues till the hand reaches the object.

2. Speed control of an automobile:

 The driver observes the speedometer, and based on the speed shown by the
speedometer he decides whether the fuel supply should be increased or decreased
or gear change is to be made.
 Here speed shown a speedometer is a feedback. A feedback signal from the eye
compares the desired speed in the memory of the driver.
 Error signals are given to brain. Brain manipulates the error signals and gives it
ton hand and leg and increase the fuel supply if the speed is less than the desired
speed, otherwise decrease the fuel supply.
 Changing of gear and increase or decrease of fuel supply, depends on whether it
an upward or downward gradient respectively.

3. Water level control of overhead tanks:

 The overhead tank has a fixed float (sensor) fixed at the desired height inside the
tanks.
 The level of the water is sensed by the float. The float has an electrical contactor,
which is positioned between fixed connectors.
 The inflow regulation valve is electrically operated. The electrical circuit of the
system is closed when the float touches the fixed connectors and open when it is
not making contact with it.
 When the level of water in the tank falls, the float moves down and makes contact
with fixed contactor and circuit is closed and pump is switched ON.

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 When the level of water rises the float moves up and breaks the circuit and pump
is switches OFF. Thereby the required level of water is maintained in overhead
tank.

4. Room temperature controller (manual):

 In this case the required room temperature will be decided by person in the room
and thus is compared mentally.
 Based on whether the room temperature is high or low, the person will operate the
switch of the room heater till the desired or comfortable temperature is achieved.
 Block diagram is illustrating the above process.

Advantages of closed loop control system -

1. More accurate.
2. Any change in system component can be taken care automatically.
3. Use of feedback system response is relatively insensitive to external
disturbances and internal variations in system parameters.
Disadvantages of closed loop control system -
1. Expensive and complicated to construction.

 Differences between open loop control system and closed loop control system

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